Mitsubishi Heavy Industries 4DQ5 Service Manual Download

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Summary of Contents for 4DQ5

Page 1: ...SERVICE MANUAL MITSUBISHI DIESEL ENGINE 4 5 ...

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Page 3: ... 8 INSPECTION AND REPAIR 16 REASSEMBLY LUBRICATING SYSTEM COOLING SYSTEM FUEL SYSTEM 37 49 52 56 ELECTRICAL SYSTEM 71 BENCH TEST MAINTENANCE STANDARDS SEALANT APPLICATION DATA 87 89 102 TIGHTENING TORQUE 103 SPECIAL SERVICE TOOLS 105 TROUBLESHOOTING CHART 110 ...

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Page 5: ...inlet connector 8 Fuel feed pipe 9 Fuel filter GENERAL 10 Fuel injection nozzle 11 0il filler cap 12 Fuel injection pipe 13 Rocker cover 14 lntake manifold 15 Fuel leak off pipe 16 Cylinder head 17 Adjusting lever 18 Hanger 1 19 Crankcase 20 Flywheel housing 21 0il pan 22 Drain plug 23 Control rack stopper 24 Governor 25 Starter 402500 ...

Page 6: ...rankcase 10 Exhaust manifold 18 Timing gear case 3 1 ndicator switch ll Elbow 19 0il level gauge 4 Flywheel housing l2 Screw plug 20 0il pipe 5 Rocker cover 13 Water pump 21 0il bypass alarm switch 6 0il filter 14 Fan 22 0il pan 7 Breather l5 Fan belt 23 0il pipe 8 0il filler 16 Alternator 2 ...

Page 7: ...Iey 20 Camshaft 3 Thermostat 12 Crankshaft gear 21 Crankshaft 4 Exhaust valve 13 Timing gear case 22 Flywheel 5 lntake valve 14 Rocker shaft bracket 23 Flywheel housing 6 Water pump 15 Rocker shaft 24 0il strainer 7 Piston 16 Valve push rod 25 0il pan 8 Camshaft gear 17 Cylinder head 26 Drain plug 9 Fan 18 Cran kcase 3 ...

Page 8: ...d 5 Tappet 6 Camshaft 7 0il level gauge 8 0il pump 9 0il strainer 10 Rocker arm 11 Rocker cover 12 Glow plug 13 Fuel injection nozzle 14 lntake manifold 15 Fuel injection pipe 16 Cylinder head 4 17 Cran kcase 18 Fuel injection pump 19 Fuel feed pump 20 Starter 21 Crankshaft 22 0il pan 402503 ...

Page 9: ... mm in 562 22 1 8 a I Overall height 629 5 24 3 4 a I Weight dry kg lb 200 441 Cylinder sleeves Dry type made of special cast iron or integral water jacket type No of piston Compression rings 2 rings Oil ring 1 w spring expander Valve arrangement Overhead Open at 30 BTDC Intake valves 50 ABDC Valve Close at timing Open at 74 BBDC Exhaust valves 30 ATDC Close at Valve clearance both intake and mm i...

Page 10: ...pe Piston valve 3 Relief valve Valve opening kg cm2 psi pressure 3 0 2 42 7 2 8 Refill capacity Oil pan liter 6 5 1 7 Oil filter U s gal 0 7 0 18 Type Piston valve Oil bypass Valve opening valve kg cm2 psi 0 8 1 2 11 4 17 1 pressure Type Centrifugal type Water pump Speed ratio to crankshaft 1 3 Capacity liter cu in 105 6408 3900 pump rpm min rpm Type Wax e Thermostat Valve opening temperature 76 5...

Page 11: ...t type with overrunning clutch cv S Manufacturer Mitsubishi Electric 9 Starter i volt Voltage output kilowatt 12 2 co l t No of pinion teeth 11 121 J No of ring gear teeth Model A001T25070 Type 3 phase AC type Voltage output volt ampere 12 35 Alternator Manufacturer Mitsubishi Electric Rated speed 5000 Working speed rpm 1000 13500 Speed ratio to crankshaft 1 68 Regulator Type IC type built in alte...

Page 12: ...adjusting plate and alternator and remove fan belt 2 b Remove bolts 1 and 3 and remove alternator 3 Remove the starter as follows a Loosen attaching nuts 1 b Remove starter from rear plate 4 Remove the fuel filter as follows a Disconnect fuel feed pipes 1 2 b Loosen attaching bolts 3 and remove fuel filter 4 8 ...

Page 13: ...nut c Loosen nuts 4 and remove fuel leak off pipe 5 d Remove nozzle assemblies 6 Remove the lube oil pipe from injection pump 7 Remove the water pump pulley and crankshaft pulley as follows a Loosen water pump shaft nut 1 and remove water pump pulley 2 b Loosen crankshaft nut 3 and remove crankshaft pulley 4 8 Remove the timing gear case 9 Remove the rocker cover 9 ...

Page 14: ...er pump assembly 2 12 Remove the rocker shaft assembly as follows a Loosen union nut 1 b Loosen short bolts 2 and long bolts 3 c Remove rocker shaft assembly 4 d Remove oil pipe 5 and 0 rings 2 pcs to be replaced with new ones e Remove valve push rods and valve caps f Remove intake manifold 13 Remove the cylinder head assembly as follows a Loosen cylinder head bolts 1 b Remove cylinder head and ga...

Page 15: ...ler gear while twisting it in the direction of its helix c Loosen injection pump drive gear nut 4 d Remove injection pump drive gear 5 16 Remove the camshaft assembly as follows Take out camshaft assembly 1 from crankcase NOTE There are tappets in crankcase this makes it ecessary to turn crankcase upside down when removing camshaft assembly 17 Remove the front plate and injection pump assembly as ...

Page 16: ...eel and rear plate 19 Remove the connecting rod bearing caps and bearings lower shells by loosening attaching bolts 20 Remove the connecting rods and pistons 21 Remove the main bearing caps by loosening attaching bolts 12 ...

Page 17: ...Remove the main bearing shells 24 Disassemble piston and connecting rod as follows a Remove compression rings 1 and oil ring 2 by using piston ring tool A b Remove oil ring spring c Remove snap rings 3 by using snap ring tool B 13 ...

Page 18: ... on both ends 1 b Remove rocker assembly 2 c Remove rocker bracket 3 d Remove rocker assembly 4 e Remove spring 5 26 Disassembly the cylinder head as follows a Remove nozzle holders b Remove glow plugs l c Loosen bolts 2 securing exhaust and intake manifolds d Remove exhaust manifold 3 e Loosen thermostat cover bolts and remove thermostat cover 4 f Remove thermostat 5 14 ...

Page 19: ...cotters 6 Depress valve spring by valve lifter h Remove retainer 7 i Remove valve spring 8 G Take out valve 9 k Remove valve guide by using valve guide remover A 15 lO Valve guide ll CyIinder head A Valve guide remover ...

Page 20: ...cations Unit mm in Item Standard Repair limit Warpage of gasketed O OS max 0 20 surface of cylinder 0 0020 0 0079 head 2 Precombustion chamber jet replacement Do not remove the jets unless they have to be re placed To remove the jet as when cracks are noted in it drive it out with a drift pin of about 6 mm 0 4 in diameter inserted through glow plug hole as shown A lntake port C Jet B Exhaust port ...

Page 21: ...ace and valve seat for wear and contact If valve face is found excessively worn reface it by using a valve refacer To reface the valve proceed as follows Item Standard Repair limit Clearance Intake 0 055 0 OS5 0 15 of valve 0 00217 0 00335 0 0059 stem in 0 070 0 105 0 20 valve guide Exhaust 0 00276 0 00413 0 0079 Valve guide 18 0 3 length out 0 709 0 012 side hole S 0 045 0 060 0 10 Intake 0315 0 ...

Page 22: ...ee cutter If valve seat width exceeds 1 6 mm 0 063 in due to wear rep lace the seat Also replace the seat when valve sinkage exceeds 1 3 mm 0 051 in Valve seat installation Chill the valve seat inserts in ether or alcohol containing dry ice Heat the cylinder head to a temperature of 80 C to 100 C 176 p to 212 p Press the inserts in the cylinder head by using the insert calking tools 30691 02700 fo...

Page 23: ... 9232 1 874 Valve spring squareness 1 5 max Load compress spring to initial working lenfth 19 1 15 43 mm 1 69 in 41 9 2 21 33 08 kg lb Exhaust manifold If the flange faces are warped by more than 0 2 mm 0 0079 in when checke l as shown grind them smooth and flat If any flange is found cracked replace the manifold_ Checking valve spring Checking valve spring for squareness Checking exhaust manifold...

Page 24: ...ng is 0 0 035 mm 0 0014 in When the sleeves are re bored oversize pistons and piston rings should be used 3 An oversize to which any sleeve worn taper and or out of round is to be rebored should be determined by relying on the most worn part of the sleeve A cylinder sleeve whose abnormal wear is 0 4 mm 0 0157 in should be rebored to 1 mm 0 0394 in oversize for example NOTE a All cylinders should b...

Page 25: ...e clearance between the sleeve and the bore is 0 08 mm 0 0031 in to 0 145 mm 0 0057 in Heat the crankcase to about 300 C 572 F Press the sleeve into the bores in the crankcase by using a hydraulic press in such a manner to make the top of sleeve protrude by 0 3 to 0 5 mm 0 012 to 0 020 in from the crankcase Then finish them to be flush with the crankcase After pressing the sleeves rebore and hone ...

Page 26: ... sloped wear Replace pistons found in bad condition 2 Measure the outside diameter of piston in two direc tions perpendicular to each other If the diameter exceeds the service limit replace the piston Specifications Unit mm in Item Standard Service limit Standard 83 90 3 3031 0 25 0 0098 84 15 3 3130 Diameter oversize 0 2 at skirt 0 50 0 0197 84 40 3 3228 0 008 oversize 0 75 0 0295 84 65 3 3327 ov...

Page 27: ...ons per engine should be 5 grams 0 18 oz max 4 Piston riD gaps Check the ring gap with a thickness gauge by placing the ring in a new cylinder sleeve and pushing the pistOll true and square in the bore Specifications Item Front of engine t Pilton _ight Piston weight marking Piston ring Gap Checking piston ring gap Unit mm in Standard Service limit 0 30 0 50 1 5 Piston ring gap 0 0118 0 0197 0 059 ...

Page 28: ...ceeds the repair limit replace the piston pin with a new one Specifications Unit mm in Item Standard Repair limit 25 0 Piston pin 0 006 diameter 0 984_8 00024 2 heck the clearance of the pin in the bushing fitted to the small end of the connecting rod by computing the difference between the two dia meter readings If the computed difference clearance exceeds the repair limit replace the pin or the ...

Page 29: ...3 If the connecting rod aligner is not available the rod may be checked as follows a To check the rod for bend measure c and 2 as shown in the figur a If the measure ment at c is larger than 0 05 mm per 100 mm 0 00197 in per 3 937 in of 2 straighten the rod with the use of a press b To check the rod for twist measure c as shown in the figure b If the measurement at C is larger than 0 05 mm per 100...

Page 30: ...is the clearance between big end and crank arm If the clearance measured exceeds the service limit replace the connecting rod or bearing Specifications Unit mm in Item Standard Service limit Connecting rod 0 15 0 35 0 50 end play 0 0059 0 0138 0 0197 6 Check the bearings as follows a Inspect each bearing for evidence of wiping or fatigue failure for scratches by dirt particles imbedded in and for ...

Page 31: ...g connecting rod bearing c Check the contact pattern of bearing on crankpin by fitting the big end in the normal manner to the crankpin with the crankshaft laid out on the bench and by using a paste of red lead or Prussian blue to visualize the con tact Be sure to tighten the cap bolts to the specified torque that is 5 5 kg m 39 8 lb ft The contact should occur over at least 75 of the entire surfa...

Page 32: ... using a surface grinder to make it flat within the specified standard Specifications Item Standard Warpage of crankcase 0 05 max gasketed surface Crankshaft 1 Journals 0 0020 Unit mm in Repair limit 0 20 0 0079 a Inspect each journal for surface flaws such as roughing scratches pitting and bums and as necessary repair the journals by grinding to the next undersize or replace the crankshaft b Mike...

Page 33: ...s exceeded repair by grinding to the next undersize or replace the crankshaft Specifications Unit mm in Item Standard Repair Service limit limit Diameter of 65 0 015 O oJ5 0 15 0 9 journals 2 559 0 00059 0 0059 0 035 0 00138 Out of round ness of crank pins and journals om 0 0004 0 03 max 0 0012 Taper of crank pins and journals Diameter of 58 0 oJ5 0 055 0 20 crankpins 228rO 00138 0 00217 0 008 0 2...

Page 34: ...ge a fillet radius is sure to cause the bearing to ride on the radius and thereby to result in a bearing failure Be extremely careful not to grind off the radius part beyond the desired dimension An over ground radius part can be corrected only by grinding off the shoulder face and this if effected will present problems in obtaining a proper end clearance Also check the crankpins and journals for ...

Page 35: ...ce between the width of thrust bearing and the dimension A indicated below 4 Runout Support the crankshaft as shown and roU it to measure its deflection with a dial gauge Distor tion is one half of the deflection dial gauge reading if it exceeds the standard reduce it by bending the crankshaft in a press Specifications Unit mm in Item Standard Repair limit Crankshaft runout 0 02 0 05 0 0008 max 0 ...

Page 36: ...ngs compute the radial clearance Specifications Unit mm in Item Standard Repair limit Fit of main bearings on 0 03 0 089 0 200 journals 0 0012 0 00350 0 00787 Camshaft 1 Check the camshaft end playas outlined for the timing gears Where the end play exceeds the repair limit replace the thrust plate with a new one Specifications Unit mm in Item Nominal Standard Repair value limit Camshaft end 5 0 0 ...

Page 37: ...r runout Straighten the camshaft in a press or replace it as necessary Specifications Unit mm in Item Standard Repair limit Camshaft runout 0 02 0 0008 0 05 max 0 0020 5 Measure the diameter of each journal in two directions to compute the fit or clearance in the camshaft hole 6 Measure the ID of camshaft holes bushings and compute the fit on each journal If the fit exceeds the repair limit machin...

Page 38: ...7 0 00236 Tappets and tappet holes 1 Inspect the riding face of each tappet for wear contact pattern and crack Replace defective tappets 2 Check the fit of the tappet in the hole against the repair limit indicated below If the limit is exceeded then replace the tappet If the hole is worn down so much as to provide an excessive radial clearance even with a new tappet the crankcase must be replaced ...

Page 39: ...nout 0 15 0 0059 max 0 5 0 020 3 Check the flywheel attaching bolt threads for condition and replace a damaged bolt if any 4 Check the ring gear for condition and replace it if damaged 5 Clean the pilot bushing which is fitted into the center bore in the flywheel and check it for condition Replace the bushing if damaged Timing gear case and oil seal l Check the timing gear case for any signs of cr...

Page 40: ...d play with a thickness gauge Replace the thrust plate to reduce the play if the thickness gauge reading exceeds the repair limit Specifications Unit mm in Item Standard Repair limit Idler end play 0 05 0 15 0 35 0 0020 0 0059 0 0138 4 If the idler shaft has to be replaced use the idler shaft puller to remove it as shown When installing the replacement shaft check to be sure that the oil holes are...

Page 41: ...r otherwise defective d Idler gear Inspect the idler gear teeth and as necessary replace the gear 6 Inspect the gear case for cracks and for evidence of oil leakage at the part ahead of the crankshaft A cracked case must be replaced Inspect the crank shaft pulley too examining condition of surface in contact with the oil seal and checking the keyway and key for wear Replace the pulley if found in ...

Page 42: ...iston so that the marking side of the connecting rod big end comes to the camshaft side c Install compression rings and oil control ring as shown by using piston ring tool NOTE No 2 ring has R or RN mark on its top side Be sure that this side is on top when the ring is in the groove 38 Combustion chamber side Camshaft side Marking side PISTON AND CONNECTING ROD ASSEMBLY PISTON RINGS INSTALLED 1 Co...

Page 43: ...ive three camshaft bushings 1 into camshaft holes in crankcase by using adapter A If the fit exceeds the repair limit machine the holes and install bushings b Drive idler shaft 2 into crankcase by using installer B CD J 8 6 9 3 OIL CONTROL RING AND EXPANDER INSTALLED Driving in DRIVING IN CAMSHAFT BUSHING 39 ...

Page 44: ... oil in the internal surface of bearing and on the external periph ery of piston Position piston rings so that ring gaps lire located 90 0 in respect with each other as shown and then insert piston assembly 2 into crankcase Alignment marks on the connecting rod must face the camshaft side Put cap attaching bolts 3 into rod in advance Insert piston assembly into crankcase by us ing piston guide A 4...

Page 45: ... I to main bearing cap 2 front center and rear and install the cap in place aligning it with dowel pin A of crankcase b Measure the crankshaft end play with a thickness gauge Replace No 1 main bearing if the end play is out of specification Tighten main bearing cap bolts 3 to a torque of 8 5 kgm 61 463 Ib ft 6 Install the connecting rod bearing caps as follows a Install connecting rod bearing lowe...

Page 46: ...external peripheries of main bearing caps No 1 and No 3 with the flange facing the case inside b Apply ThreeBond 1102 adhesive on both sides of oil pan gasket 2 and attach it to crankcase Make sure that the gasket is completely attached in the grooves A in the caps c Apply Atomjet on the both ends of rubber packing 3 and insert the packing into cap 42 ...

Page 47: ... bearing cap Tighten the bolts to a torque of 0 4 kgm 2 9 lb ft 8 Install the front plate as follows a Apply ThreeBond 1102 to the both sides of front plate packing and attach the packing to the front face of crankcase Secure front plate 1 with in jection pump installed with two bolts 2 The tightening torque of the bolts is 2 1 kgm 15 2Ib ft b Heat camshaft gear to 150 C to 180 C and fit it to sha...

Page 48: ...otation Using a 3 mm 0 12 in thick smooth steel plate add 3 mm 0 12 in clearance to intake and ex haust valves of No 1 cylinder Then insert a 0 05 mm 0 0020 in thickness gauge into between the top of valve cap and rocker and slowly turn the crankshaft trying to find a position where the thickness gauge is firmly gripped the valve starts opening and a position where the gauge is just ungripped the ...

Page 49: ...e rear plate and flywheel as follows a Drive in dowel pin 1 and secure flywheel 2 complete with pilot bearing in place with bolts 4 and lock washers 3 b Bend lock washers properly to lock bolts Flywheel bolt tightening torque Unit kg m lb ft 8 S to 5 61 5 t 3 6 13 Reassemble the cylinder head as follows a Drive valve guide 2 into cylinder head 1 as shown 45 B 1 CYlinder head 2 Valve guide A Valve ...

Page 50: ...d 14 Install the cylinder head assembly as foJIows a Place the gasket 1 to crankcase 2 and install cylinder head 3 Use two guide bolts 4 to prevent the gasket from moving when placing cylinder head to the crankcase CAUTION Do not apply any sealant to the gasket b Tighten the cylinder head bolts to a torque of 12 kg m 86 8 lb ft at exhaust side and at intake side in the sequence shown below CYLINDE...

Page 51: ...25 mm 0 0098 in for both intake and exhaust valves This value assumes that the engine is at normal tempera ture there being no temperature difference throughout the body of the engine The checking and adjusting procedure is as follows a Rotate the crankshaft slowly to bring the piston in No 1 cylinder to Top Dead Center TOC This can be accomplished by observing rocker arms of No 4 cylinder As you ...

Page 52: ...e water pump pulley and crankshaft as follows a Drive in water pump pulley 1 and crankshaft pulley 2 by using installers A and B b After driving in the crankshaft pulley install washer and tighten nut Then bend the lock washer to lock the nut 21 Install the alternator 22 Install the fan belt as follows a Attach fan belt to the pulley b Adjust the fan belt tension in such a way to have a slack of 1...

Page 53: ...ide the crankcase at its right hand rear portion Its main shaft is driven from the skew gear formed of the camshaft 2 1 Disassembly 1 Loosen bolts securing oil strainer 2 and separate the strainer from oil pump case 2 Loosen bolts 3 securing oil pump cover 4 and separate the cover from oil pump case 3 To facilitate removal of outer rotor 5 turn the pump case upside down 4 Drive out pump drive gear...

Page 54: ...clearance between outer rotor and pump body Insert a thickness gauge into between outer rotol and body If the clearance checked is greater than the limit replace the worn part Specifications Unit mm iR Item Standard Repair limit Clearance of outer 0 2 0 275 0 50 rotor in body 0 0079 0 01083 0 020 4 Rotor shaft diameter Inspect the shaft for damage and check it for wear by miking Determine the avai...

Page 55: ... element is actually a relief valve located in the center portion of the element This valve is set to open when the differential pressure across the element rises to 1 0 0 2 kg cm2 14 2 2 8 psi when the valve opens the oil flows directly from inlet side to outlet side The filter element must be serviced regularly or before the element becomes so dirty as to actuate this bypass valve The oil filter...

Page 56: ...ng coolant temperature reaches 765 C 169 7 F the thermostat valve begins to open increas ingly wide and the coolant begins to flow to radiator G at a rising rate of flow with a corresponding decreases in the amount of coolant being bypassed As the tem perature reaches 90 C 194 F the valve becomes full open shutting oU the bypass passage_ 2 Thermostat The thermostat is of wax type designed to start...

Page 57: ...s are lubricated by engine oil fed from the main gallery within the crankcase The impeller is threadedly mounted on the pump shaft E E 9 iii 0 Tl Temperature 76 5 2 C 169 7 3 6 F 1 that makes valve start opening Tz Temperature 90 2 C 194 3 6 F that makes valve fully open with a lift of not less than 9 mm 0 35 in Thermostat performance curve 3 1 Disassembly 1 Remove pump cover 2 by loosening covera...

Page 58: ... check for the cause The impeller and case or cover if found damaged due to rubbing must be replaced with new ones 3 Check the unit seal for condition Replace the seal if it is badly worn or damaged 4 Check the pump shaft bearing journals for wear Replace the shaft if the journals are excessively worn 5 Check those surfaces of pump case to which the bearings are fitted for excessive wear or damage...

Page 59: ...d install the shaft in pump case 3 2 Install snap ring 4 in case on pulley side 3 Install unit seal 5 in impeller 6 and secure the impeller to the shaft 4 Install cover 7 5 Rotate the shaft to check to see that the impeller does not interfere with cover 55 ...

Page 60: ...its injection nozzle through its own injection pipe These shots are synchronized to the diesel cycle in each cylinder and timed by the setting of the timing mecha nism Injection quantity or the amount of fuel delivered uniformly by the four pump elements to the engine through their injection nozzles is controlled from the accelerator through a linkage and automatically adjusted by the injection pu...

Page 61: ... the mounting bolts 2 Install fuel feed pipes and lube oil pipe and reconnect all but No 1 fuel injection pipe 3 Crank the engine slowly until the plunger in No 1 pumping element comes to the position for beginning of injection Check to be sure that the timing mark on crank pulley is matched to the pomter on the timing gear case if not adjust the mounted position of the pump in the follOwing manne...

Page 62: ...t being pushed up by their push rods 2 Inspecting fuel injection timing a Remove the delivery valve holder from No 1 pumping element of injection pump Take de livery valve and spring out of the holder and restore the holder to the pump b Turn the crankshaft to bring No 1 piston to about 60 position before top dead center on compression stroke c While operating the priming pump to allow fuel to flo...

Page 63: ...r Check for cracks distortion or other damage and also for stripped threads Replace the case and cover if found in defective condition 2 Connector bolts and plug Check for defective threads replacing them if damaged 3 Gaskets Discard gaskets removed in disassembly Be sure to use new gaskets in each reassembly NOTE Do not wash the element for re use 59 l Bolt 2 Gasket 3 Cover 4 Air vent plug 5 Case...

Page 64: ...ning nuts 5 3 Using a wrench remove nozzles from cylinder head as shown Also remove nozzle packings with a wire or screw driver Replace a defective packing if any 4 Install injection nozzles in the reverse order of removal Tighten nozzle holders to a torque of 5 kg m 36 2Ib ft NOTE Cover the injection pipe and cylinder head openings to prevent entry of dust or foreign matter after removing the noz...

Page 65: ... age at its seating part and for wear of its end face in contact with the pressure pin d Poor seating contact may be corrected if the defective condition is not advanced too far by lapping the valve against the seat with a coat of clean lube oil applied to the seating faces If this does not help the injection nozzle must be replaced 2 Nozzle holder and distance piece Check the fit between nozzle h...

Page 66: ...e the thickness of the shim used on the pressure spring Increasing the shim thickness by 1 mm 0 04 in raises the injection pressure by about 10 kg cm2 142 psi Adjusting shim stock for this purpose is available in 20 sizes from 1 0 mm 0 0394 in up to 1 95 mm 0 0768 in in increments of 0 05 mm 0 0020 in each 2 Spray pattern The injection nozzles used in the present engine are of throttle type Some t...

Page 67: ... second the initial throttle spray is hardly visible The spray under this condition may be regarded as main spray The main spray should be a good straight cone consisting of fmely atomized fuel particles without any large droplets and should termi nate with no dribble at the tip not to mention of any fuel dripping 3 Seating tightness An injection nozzle tested and adjusted as above and found to pr...

Page 68: ...ve stem bore 6 Fuel feed pump The camshaft in the bottom section of the injection pump has an eccentric cam besides the cams for actu ating the individual pump elements By this eccentric cam the pumping plunger of the feed pump is actuated to draw fuel through the inlet strainer and forward it to the injection pump A means of manually priming the fuel circuit is provided in this pump It consists o...

Page 69: ...mp 2 and take out check valve 3 Priming pump cannot be disassembled as the cylinder and valve holder are ad hered with adhesives 2 Loosen piston chamber plug 4 and pull out piston spring 5 and piston 6 3 Remove ring 7 and take out tappet 8 and push rod 65 ...

Page 70: ...ler pin involving the pin hole and roller is prescribed to be not greater than 0 3 mm 0 012 in If this limit is exceeded the whole tappet sub assembly must be replaced Replace the roller if its diameter has worn down to the service limit Specifications Unit mm in Item Standard Service limit 0 Tappet roller OD 15 0 027 0 075 0 591j 00106 0 00295 3 Pump housing damage Inspect the housing for cracks ...

Page 71: ... the discharged fuel Under this condition the pump should deliver at least 900 cc 54 9 cu in miDute Specifications Item Standard Repair limit 900 cc 55 600cc 37 Feed pump cu in minute cu in minute capacity minimum at at 1000 rpm 1000 rpm 4 Air tightness Immerse the feed pump in a pool of fuel with its discharge side plugged up Apply an air pressure of 2 kg cml 28 psi to its suction to see if any b...

Page 72: ...ar ratio of 2 to 1 For each two rotations of crankshaft the injection pump cam shaft rotates once The pump element consists of a plunger barrel cylinder tappet plunger spring control pinion and spring loaded delivery valve The tappet rides on the cam and pushes the plunger upward for each rotation of camshaft As the plunger rises the fuel in the barrel becomes compressed and is forced out through ...

Page 73: ...ion volume 51 mm3 0 003 cu in stroke Injection order 1 3 4 2 Injection interval 90 0 30 8 Governor l Stopper lever l2 Arm 2 0il inlet l3 Shackle 3 Control spring l4 Flyweights 4 Screw plug l5 Bearing 5 Stopper l6 Governor gear 6 Control lever shaft l7 Slip disc 7 Shackle pin l8 Shim plate 8 Floating lever 19 Camshaft 9 Connecting pin 20 Camshaft bushing 10 Connecting bolt 2l Control lever shaft 11...

Page 74: ...al force is transmitted to arm to push governor sleeve through thrust bearing To this sleeve is attached adaptor spring This spring opposes the force of control spring through spring seat so as to compensate for a decrease in torque when the engine is running at low speeds Floating lever is hinged at its lower end to supporting lever IT mounted on control lever shaft C and is connected at its uppe...

Page 75: ... Glow plugs Sheathed type ELECTRICAL SYSTEM Manufacturer Mitsubishi Electric Mitsubishi Electric Hiyoshi Electric Battery charge lamp Glow plug indicator Starter switch s Battery 12V 100AH Wiring diagram 71 Glow plugs Wire sizes 40 ODd 5 ODd 1 25 ODd 0 5 ODd ...

Page 76: ...nning clutch 12V 2 kW Series 80 mm 3 15 in 30 seconds Clockwise as viewed from pinion side 5 8 kg 12 8 lb approx Condition Voltage 11 V Voltage 3 V 1 Switch assembly 2 Front bracket 3 Lever assembly 4 spring set 5 Bearing 6 Pinion 7 Pinion shaft Specification Current 130 A max Speed 4000 rpm min Current 1000 A max Torque 2 8 kg m 20 3 lb ft min 8 V max 72 a Gear 9 Center bracket 10 Yoke 11 Armatur...

Page 77: ...lnner race 5 Pinion a Pinion meshed in flywheel As the outer race rotates the rollers are jammed tight between the inner and outer races to lock these races Now the torque from the armature is transmitted from the outer race to the inner race and then to the pinion b After the engine starts it spins the pinion inner race faster than outer race The rollers are ro tated into the free state by the sp...

Page 78: ...Voltage regulation 14 4 0 3 V 4 Stator 5 Front bracket 6 Rear bracket 7 IC regulator a Rectifier 9 Bearing 2 Construction of alternator 74 This alternator has a built in IC regulator The rotary parts are rotor ball bearings fan and pulley The stationary parts are stator front bracket and rear bracket The rectifier consists of a total of six diodes three diodes on the positive side are mounted on t...

Page 79: ... 3 Alternator operation a Starter switch in M position _ JI _Fuse box Alternator t Ie regu lator b Starter switch in S position and starter operates Fuse box _ JJ7f l _ 75 1 Battery 1 Battery ...

Page 80: ... three diodes to transistor Ql causing transistor Q2 to turn off Under this condition the field current is reduced to weaken excitation of the rotor and consequently output voltage begins to fall 76 Fuse box tII I Battery When output voltage has sufficiently dropped zener diode Dz permits no current to flow Now transistor Ql turns off and transistor Q2 turns on and consequently the field current i...

Page 81: ... between the battery and starter and wire 2 between the starter and starter switch 2 Unscrew mounting nuts 1 and remove starter as sembly 2 from the engine To install follow the reverse of removal procedure 1 Nut and washer 2 pcs each 2 Starter assembly 77 ...

Page 82: ...17 Front bracket 9 Center bracket The parts are numbered in the sequence of removal for disassembly To reassemble follow the reverse of disassembly procedure 1 Loosen the nut on the switch terminal M and remove the connector Remove the switch by pull ing the screws 2 pcs 78 2 Pull the through bolts 2 pcs remove the brush holder screws 2 pcs and remove the rear bracket NOTE Take care not to drop th...

Page 83: ...ng the pinion shaft axial play 7 Remove the snap ring holding the pinion and re move the pinion 8 Remove the lever springs large and small lever reduction gears pinion shaft etc 79 NOTE Lay the lever and springs in the order removed so that they can be restored to their original positions 9 Replace the ball bearings The ball bearings fitted to the ends of armature can be removed with a bearing pul...

Page 84: ...6 Pulley 7 Fan 8 Diode 9 Brush 10 Nut 670355 80 1 Pull the three through bolts and break the alter nator into the rotor complete with front bracket and pulley and stator complete with rear bracket 1 Bolt 3 pcs 2 Front bracket 3 Rotor 4 Stator coil 5 Rear bracket 6 Pulley 2 Hold the rotor in a vise Unscrew the pulley nut and remove the pulley 3 2 Front bracket 3 Rotor 6 Pulley 7 Fan To reassemble f...

Page 85: ... are free of any insulation stripping due to fraying there being no signs of grounding or breaking 5 The starter switch closes and opens the circuit positively at each position 81 Do not jump into a conclusion that th e starter is in trouble when the engine refuses to fire up upon cranking the engine could be in trouble b No load test If the starter is suspected of trouble take it down from the en...

Page 86: ...e The best way of testing the starter is to run it under loaded condition but that requires special testing equipment For ordinary servicing pur poses the no load test and troubleshooting guide will do 2 Inspection after disassembly a Using a ground tester or megger check armature coil and commutator for short circuit If there is any continuity between commutator and ar mature shaft armature coil ...

Page 87: ... to shift against stopper Under this con dition push pinion back and measure gap 83 Battery 12 V Pinion gap Pinion Specifications Unit mm in Item Pinion gap Assembly standard 0 5 2 0 0 020 0 079 NOTE To adjust pinion gap increase or decrease thickness of washers used between mating faces of magnetic switch and front bracket f No load test After adjusting pinion gap connect starter and battery with...

Page 88: ...lowing to the ammeter start the engine If the charging current is below 5 amperes when the engine is running at about 2000rpm read the voltmeter If it exceeds 5 amperes charge the battery for a while or replace the battery with a fully charged one Another method is to connect a 1 4 ohm 25 W resistor in series with the battery to limit the charging current The regulated voltage should be 14 1 to 14...

Page 89: ...t or repair Fan belt tension Loose connections open short circuit in charging system wiring Trouble of charging system due to defective battery b Output test on a test bench Remove the alternator from the engine Connect it in a test circuit as shown at upper right and operate it by a motor for testing Close the switches Kl and K2under the state where very little load current flows in the test circ...

Page 90: ...y brush which is worn beyond the service limit should be replaced with a new one Wear limit line J20198 7 3 Battery Check the electrolyte level in the battery cells making sure that it is 10 mm 5 16 in above cell plates Check the specific gravity of electrolyte If it is below 1 260 at 20 C 68 F prepare an electrolyte of 1 260 specific gravity and add it to the battery A specific gravity below 1 19...

Page 91: ... is in good condition c Color of exhaust gases d Leakage of cooling water e Leakage of fuel oil f Fuel injection 3 Running in the engine While running in the engine check the following items and repair if necessary a Oil pressure 3 4 kg cm2 or 42 7 56 9 psi b Temperature of cooling water 75 85 C or 167 185 F c Temperature oflubricating oil 60 70 C or 140 158 F in oil pan d Abnormal noise e Excessi...

Page 92: ...760 11 4 K H Hw Where H Hw t 273 t 293 atmospheric pressure inmmHg partial pressure of vapor in atmosphere in mmHg room temperature in c CF 88 ...

Page 93: ...8 4 psi Oil temperature 70 C 158 F 1 2 kg cm2 04 2 28 4 psi min 0 5 kg cm2 at idle speed 7 1 psi 24 ATDC 4 BBDC These values are to be referred to in measuring timing and 13 16 BBDC differ from actual timing 28 BTDC ngi ne specifications rpm 1150011800 I 2000122001250013000136001 Standard values are shown E BTIJ 1 23 I 24 I 25 I 26 1 28 I 30 I 33 I Check timing on caution plate A lt r _ F I fJiGQ ...

Page 94: ...1 Replace crankcase and 0 0079 0 9 0 035 limit is reached bearing cap as an assembly Regrind crankshaft 0 Q35 0 100 at crankshaft journals and use under 2 Upper bearing shells have 0 00138 0 00394 1 journal aD size bearings 0 25 oil groove 0 0098 0 50 0 0197 1 or 0 75 0 0295 if service limit is reached 0 E9rH I 0 1 0 189 1 0 004 0 00744 0 30 1 0 0118 Replace thrust bearing 8 033 tg OO13O 0 10 0 00...

Page 95: ... 0 20 J repair limit is reached 0 00276 0 00413 0 0079 0 a C Valve sinkage L3 to 0 8 0 031 0 2 0 008 Go 0 051 c C 3 Margin valve head 1 f I 1 7 0 067 1 2 a thickness 0 047 Refacing limit Face runout of stem 0 03 0 0012 max prependicularity to valve face Valve guide length 18 0 709 0 3 0 012 outside hole Valve seat angle 30 Valve seat width 1 4 0 055 0 14 O OOSS 1 6 0 063 Free length 48 85 1 9232 4...

Page 96: ...9 65 2 559 5S 2 2S3 3 0 12 Unit mm in Assembly standard Repair limit Service limit Standard clearance Clearance Clearance Remedy Remarks 0 25 0 009S clearance may also be obtained by warm set ting if intake and exhaust valves are at the same temperature g 061 tg 00240 0 016 CO 00063 0 034 0 00134 Replace bushings if 0 016 0 095 1 0 10 J repair limit is rcached 1 0 00063 0 OO374 J 0 0039 Replace sh...

Page 97: ...197 CJ oversize E is 0 75 0 0295 oversize Protrusion above crankcase Difference in weight among pistons per engine Unit mm in 47 1 850 0 05 0 0020 om 0 0004 max as runout 83 90 3 3031 e 84 15 3 3130 Measure in the direction 0 015 0 2 0 00059 0 008 transverse to piston pin 84 40 3 3228 84 65 3 3328 1 0 35 0 75 r 0 0138 0 0295 Check bcarin clearance f 5 g 0 18 oz ...

Page 98: ... 00138 0 00394 Unit mm in Repair limit Service limit Remedy Remarks Clearance Clearance Compress rings to 84 3 31 dia 1 5 I 0 059 oo C o c Ring side clearance 0 20 Measure side clearance 0 0079 with ring kept flush with Replace rings if service second land limit is reached Re place pistons if the limit is exceeded CD 0 15 ell 0 0059 l Compression ring 2 Straightedge 3 Piston 2 When replace oil rin...

Page 99: ...shing End play 26 1 02 Unit mm in 0 15 0 35 0 0059 0 0138 0 50 0 0197 Replace connecting rods 25g iO 88 oz Grind or replace I 0 15 0 0059 max 0 5 0 020 Replace flywheel I DI D2 DI D2 6 684 I 6 184 0 26315 0 24346 Replace camshaft I DI D2 7 344 DI D2 I 0 28913 6 844 0 26945 D2 0 04 CO 0016 0 06 0 0024 0 05 0 02 0 0008 max 0 0020 Straighten or replace 0 05 0 112 0 3 Replace thrust plate I 0 00197 0 ...

Page 100: ...0 5 1 5945 13 0 5118 3 0 kg cm2 42 7 psi 20 0 78 15 0 591 7 0 276 7 0 276 1 8 2 2 kg cm2 25 6 31 3 psi Unit mm in Assembly standard Repair limit Service limit Standard clearance Clearance Clearance Remedy Remarks 0 05 0 15 1 Q0020 0 0059 0 35 0 0138 Replace thrust plate 0 09T 0 045T O 0035T 0 0018T J 0 05 0 20 0 25 Replace gear 0 0020 0 0079 0 0098 1 0 013 0 Q15 0 00051 0 00059 1 0 25 J 0 0098 1 0...

Page 101: ...x with pump running at 1000 rpm 0 02 0 062 I 0 00079 0 00244 j 15 0 591 o 0 0 027 0 00106 I 49 4 0 945 1 to 039 o 0 44 1 732 32 1 260 0 5 0 020 1 32 1 260 o 0 1 0 0 004 Unit mm in Check displacement with injection pump operated at 1000 rpm with a discharge pressure of 1 5 kg cm2 21 psi Close pump discharge port with a plug Apply an air pressure of 2 kg cm2 28 psi to the pump and keep the pump imme...

Page 102: ...30 1 0 2 0 3 I 0 008 0 012 Test conditions Nozzle tip Injection pipe Injection pressure Delivery pressure Test oil Pump speed Rack position rpm mm 2000 8 5 0 335 1000 1000 8 0 0 315 200 6 0 0 236 7 0 276 0 019 0 047 1 0 00075 O 00185 1 11 0 433 0 016 0 052 1 0 00063 0 00205 1 0 06 0 12 I 1 0 0024 0 0047 Unit mm in Repair limit Service limit Remedy Remarks Clearance Clearance 0 15 0 0059 0 1 Adjust...

Page 103: ...ace floating lever 0 00039 0 00205 0 08 I or pin 0 0031 Replace shackle or shackle pin 0 01 0 055 I 0 00039 0 00217 Replace shackle or bushing I 0 025 0 07 I 0 00098 0 00276 I 0 2 I 0 008 Replace shaft or bushing 0 02 0 3 I I 0 18 I Adaptor should slide 0 0008 0 0051 0 0071 smoothly in a dal direction Adjusting lever angle Pump rpm Control rack position RW mm in 4 5 1150 8 3 8 7 0 327 0 343 1400 3...

Page 104: ...ne droplets 200 e or 68 F approx If No dribbling should be ob 0 SI IY pattern is improper served after each injection even after nozzle is washed in dean kero Throttle injection should sene replace nozzle tip occur when the tester lever is operated slowly Scat shall show no sign of leakage under a pressure of Wash needle valve scat Replace nozzle tip when 100 kg cm2 1422 psi or replace nozzle tip ...

Page 105: ...acteristic Locked rotor characteristic Magnetic switch operating voltage Voltage V Current A Rpm Voltage V Current A Torque Switch IN Switch OFF 12 130 max 4000 min 3 1000 max 2 8 kg m 20 3 8V max When circuit is e lb ft min opened III ia u 5 o u No load battery connected Under load battery resistance load 30A connected IC regulator Voltage V Current A rpm Voltage V Current A rpm Adjusting voltage...

Page 106: ...ly to the whole surfaces at reassembling Gear case Apply when reassembling Timing gear case ThreeBond 1102 temporarily gasket Front plate Apply to the whole surfaces at reassembling Plate Apply when reassembling Water pump gasket ThreeBond 1102 temporarily Water pump Apply to the whole surfaces at reassembling Plate Apply when reassembling Pump plate gasket ThreeBond 1102 temporarily Crankcase App...

Page 107: ... 3 6 Timing gear case bolts 1 0 0 5 7 2 3 6 Camshaft thrust plate bolts 1 8 0 5 13 0 3 6 Idler thrust plate bolt 3 5 0 5 25 3 3 6 Crankshaft pulley nut 40 0 t 0 5 89 3 3 6 Rear plate bolts 3 5 0 5 25 3 3 6 Rear oil seal bolts 0 4 2 9 Flywheel bolts 8 5 0 5 61 5 3 6 Oil pan bolts 0 7 5 1 Oil pan drain plug 10 0 0 S 72 3 3 6 Nozzle holder retaining nuts 5 0 0 5 36 2 3 6 Injection pump delivery valve...

Page 108: ... including 14 kg m 10 I Ib ft has a tolerance of 20 and a torque above 14 kg m 101 Ib ft has a tolerance of 15 Tightening torque With spring washer Without spring washer Diameter Pitch kgf m lbf ft kgf m Ibf ft 8 1 0 1 8 1 2 2 16 1 25 1 8 13 2 1 15 10 1 25 3 6 26 4 2 30 1 5 3 4 25 4 0 29 12 1 25 6 5 47 7 6 55 1 75 6 0 43 7 1 51 14 1 5 10 4 75 12 2 88 2 0 9 8 71 11 5 83 16 1 5 15 8 114 18 6 135 2 0...

Page 109: ...ng or sketch Qt lC 55 Material S53C O 5C lC 1216 158 188 Material S53C 105 Unit mm Used for Installing valve guides l Valve guide installer 2 Valve guide I 3 Cylinder head A Guide length outsi de hole Removing valve guides 0 l Valve guide remover 2 Valve guide 3 Cylinder head I Installing 1 A intake valve t inserts valve ins rts 1 Caulking body 4 Valve guide 2 Valve insert 5 Caulkmg ring 3 Cylinde...

Page 110: ...shaft puller Cranking handle 34491 00300 Socket Drawing or sketch 106 Qt Unit mm Used for Connecting pressure gauge to engine for compression measurement Placing pistons in crankcase Removing idler shaft I I I n t I i Rotating crank pulley for engine cranking Installing camshaft thrust plate ...

Page 111: ... 31391 12900 Piston ring tool Idler bush 30691 51900 ing puller Drawing or sketch 107 Qt Unit mm Used for Installing cylinder sleeves l Cylinder sleeve 2 lnstaller 3 Cran kease Tightening fuel injection pump mounting bolts Removing installing piston rings Removing installing idler bushing ...

Page 112: ...et Sleeve installer set Drawing sketch Adaptor MH061080 Adaptor MH061 081 108 Qt Unit mm Used for Removing installing camshaft bushings 1 Rod 3 Camshaft bushing 2 Adaptor To be used together with guide piece 30891 04700 as a set Installing crankshaft rear oil seal sleeve ...

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Page 114: ...vanced Injection timing too retarded Defective governor control spring Maladjusted governor damper spring Engine speed too low Failure of engine to stop properly Poor grade of fuel oil Fuel viscosity too high Poor grade of oil Oil viscosity too high Oil viscosity too low Low oil pressure Excessive oil leakage Pumping up of oil Clogged oil filter Defective oil indicator switch or lamp Insufficient ...

Page 115: ... cro 0 c s n o 0 cro n Q i I C 0 0 I 0 I I I 0 0 0 I 0 I I I I I I I I I I I 0 I I I i I I I I I I I I I 0 0 0 0 I I I I I I I I I I 0 0 I 0 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 0 I I I I I I I I I I I I I I I I I I I I r 0 0 n i I n 0 0 N N C 0 0 n n l 0 I 0 0 I I I 0 I I I I 0 I I I I I I I I I I I I I I I I I I I I I I I Engine vibrates excessively Engine stalls Poo...

Page 116: ...age drop Open circuit in heater plugs or pilot lamp Short circuit in heater plugs Defective alternator Defective alternator relay Improper wiring Jammed moving parts Worn cylinders pistons or piston rings Sticking piston rings Excessive main bearing clearance g Loose connecting rod cap bolts E Interference between valve and piston Broken valve springs Excessive valve clearance Foreign substances i...

Page 117: ...engine thoroughly 0 0 0 0 0 0 0 0 0 0 0 Retighten and replace gasket if necessary 0 Replace crankcase Check for connections and repair Replace if necessary 0 Repair or replace if necessary Repair or replace Repair or replace motor if necessary Repair or replace ring gear Replace pinion 0 0 0 Recharge or replace battery If necessary heat it Replace Replace copper packings and if necessary heater pl...

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Page 120: ...Dec 85 Printed in Japan Pub No 99609 1 01 011 ...

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Mitsubishi Heavy Industries 4DQ5, Service Manual

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